Boat construction



July 16, 1935. H. J. GONYER 2,008,136

BOAT CONSTRUCTION Filed Jan. "3, 1954 2 Sheets-Sheet 1 AAAAAA July 16, 1935. H. J. GONYER 2,008,136

BOAT CONSTRUCTION Filed Jan. 5, 1954 2 sheets-sheet 2 Patented July 16, l1935 BOAT CONSTRUCTION Harry J. Gonyer, Milton,` Mass., assignor to Gonyer and Benson, Canton, Mass., a partnership consisting of Harry J, Gonyer, Milton, Mass., and Philip Benson, Cohasset, Mass.

Application January 3, 1934,'SerialNo. 705,052

9 Claims.

This invention relates to hulls for boats and the like and to a method of making the same. More particularly, the present invention relates to hulls adapted to be employed in small craft such as in row boats, duck boats, small sailing and motor boats, pontoons, etc.

Hulls for small craft have commonly been made of wood. Among the advantages of Wood for hull construction are its toughness and stressresisting ability, which particularly permit it effectively to withstand the rough usage to which boats are commonly subjected, while wood is also capable of ready Working and is naturally buoyant. Wooden boats, however, have numerous seams which are likely to cause leaks and require calking. Furthermore, wooden boats require frequent renishing and repainting. Small craft constructed of other materials have generally compared unfavorably with Wooden boats due, for example, to the inability of such craft, if reasonably light and buoyant, to withstand rough usage without rupture, denting or tearing, or due to a tendency to deteriorate when alternately immersed in the water and dried in the sun, or due to gradual deterioration on account of oxidation. Furthermore, many of these substitutes for wood have necessitated expensive manufacturing equipment and operations, requiring, for example, expensive dies or moulds, careful joining of seams, construction of comparatively elaborate frames, etc.

It is an object of the present invention to afford a hull having structural strength and resiliency comparable to that of a high grade wooden hull, while affording a continuous durable surface which does not require additional finishing. Furthermore, this invention permits hulls readily to be constructed with different shapes and contours, at a cost comparing favorably with that of wooden boats of a similar size and weight. This method of boat construction does not require elaborate manufacturing equipment, or highly skilled craftsmen. Thus small establishments may economically manufacture boats in small lois or individually to suit local requirements.

To permit these desirable results, a matrix body of set plastic material may be arranged to afford the major structural strength and formretaining ability of the hull. Embedded within the matrix body is a core layer of foraminous or reticulated material, preferably comprising a coarsely meshed wire sheet or sheets readily deformable per se. 'Ihe wire forms a base for the application of the plastic material and is especially advantageous in aiding the setting of the material in proper form. While the matrix body affords the major structural strength of the completed hull, the core layer of Wire aids in opposing tensile and shearing strains.- While parts such as the gunwale strips, thwarts and keel or skeg may be made integral with the body of the hull, they are more conveniently provided by separate pieces of wood. In general, however, a boat constructed in accordance with this invention is characterized by an integral. hull body formed of tough, stiff, yet resilient material Without'requiring reinforcement by auxiliary `elements such as ribs or stringers.

For the matrix body I preferably employ a plastic or viscous composition capable of setting to afford a tough, resilient structure and capable of maintaining a very secure adhesive attachment to other materials such as the metal of the core layer and the wooden parts, such as a keelson and stern board that may be included in the hull. I prefer a viscous compound including a volatile solvent, particularly a cellulosic composition including a discrete filler and one or more plasticizing ingredients to prevent gradual deterioration due to oxidation and consequent development of brittleness.

The method of hull construction described herein permits the satisfactory employnent of such a matrix body, despite a tendency toward shrinkage upon drying due to the loss of volatile solvent.

In the accompanying drawings:

Fig. 1 is a cross section of a form and a partially completed hull thereon;

Fig. 2 is a view partly in longitudinal section and partly in side elevation with parts broken away to show the manner in which the hull is partially constructed over a form;

Fig. 3 is aside elevation of the partially formed hull before the inner lamina of plastic material has been applied;

Fig. 4 is a rear view of a boat constructed in accordance with this invention, a portion of the plastic material being removed to show the construction which may be employed when a stern.

board is used;

Fig. 5 is a side elevation of the completed boat with parts broken away;

Fig. 6 is a top View of the completed boat;

Fig. 7 is a view on line 'I-l of Fig. 6;

Fig. 8 is a section indicated by line 8-8 of Fig. 5; and

Fig. 9 is a section on line 9-.9 of Fig. 2.

To construct a boat in accordance with this invention, a form l preferably is first provided to conform accurately to the shape of the finished boat, but to have cross-sectional 'dimensions slightly larger than the corresponding dimensions of the interior of the finished hull and to'have a substantially greater depth. Such a form may conveniently be built up from wood to provide a surface of planking Vsubstantially defining the shape of the interior of the hull. This invention may be employed in making` hulls of many different shapes, for example, hullshaving both pointed prows and sterns, but for purposes of illustration I have shown herein a construction wherein a planar stern board is employed. With this type of construction, obviously the rear portion of the form l is provided by a planar board or board assembly. Such a form is illustrated in Figs. 1 and 2 and is inverted so that the curved lower surface corresponding to the keel portion of the boat is disposed uppermost. Preferably a form of this character is characterized by a central groove 2 adapted to receive a keelson strip, thus aifording means accurately to center 'the hull structure on the form and aording convenient means to aid the joining of the wire sheets which constitute the core layer.

When a hull is to be made, sheets of oiled paper 5 'may be laid over the form i and a layer of cheesecloth 6 may then be placed over the paper. A wooden keelson strip 4 is located in the groove 2, as shown in Fig. 1, and the meshed wire screen is then laid on the fonn. This screening preferably may consist of two sheets I0 each conforming in dimensions substantially to the dimensions of one-half of the hull. As shown in Fig. 1, the

margins of the sheets may oe lapped one over the y other and their edges may be secured to the keelson strip I, thus affording means accurately to position and center the core layer in relation to the form. At the pointed prow of the boat the ends of the wire sheets I0 may be lapped over each. other and clinched in place in the manner particularly illustrated in Fig. 9. When a boat having a stern of similar shape is being constructed, a similar arrangement may be employed at the rear of the form, but when a boat having a sternboard is being constructed, such a board Il preferably is cut out of wood and temporarily mounted on the back of the form and secured to keelson 4. The ends of the wire sheets l0 are 'folded over and held against the stern board by lapped, clinched engagement and with their edges joined together and connected to the keelson strip 4, While the rear edges of the sheets are lapped over and secured to the stern board I5.

The lower edges of the wire sheets as they are applied to the form preferably project below a line indicated by the dotted line L in Fig. 2, which is marked on the form and corresponds to the upper edge of the hull. The portion of each wire sheet depending below line L is secured against the form by any temporary fastening means, such as tacks or nails, or by a suitable retaining band of flexible sheet metal. In this condition of the parts it is evident that the Wire is held tightly against the adjoining surface of the sheet .material 6. y

'I'he outer layer or lamina of plastic material may then be applied'to the skeletonized structure which is secured to the form. For this purpose I prefer to employ a composition including cellulosic material together with an ingredient or ingredients having a plasticizlng and antioxidizing eifect and also including a substantial quantity of a discrete filler. I have found compositions containing the following ingredients 'and falling between the indicated limits to afford especially desirable results (proportions are by weight) Obviously the specific ingredients and proportions of ingredients of such a plastic composition may be considerably varied, .as desired. In many cases, a desirable composition is afforded by an admixture having proportions somewhat nearer to those of a mixture including the minimum proportion of solvent than to those of a mixture having its constituents in proportions that are substantial averages of the above ratios. Various solvents such as methyl acetone and benzol may be employed with or without an admixture of methylated spirit, while the non-drying oil may be convenient-ly in the form oi.' a vegetable oil such as castor oil. 'Ihe nitrocellulose may be conveniently in the form of celluloid scrap; obviously cellulose acetate or analogous substances may be employed in place of the nitrocellulose. The resinous constituent may be ester gum or any suitable synthetic resin. While I prefer to employ wood our as the filler, various other discrete or comminuted substances may be employed with or substituted for the wood our.

It is desirable, however, to provide a illler which about the filler particles so that the finished hull may be impervious to water. In-certain cases it may be desirable to employ a powdered pigment in place of some of the filler, thus permitting the hull body to receive a distinctive color without necessity for special iinishing operations.

The plastic material may be applied to the wire mesh upon the form by troweling, the first layer of the material being pressed into the meshes of the wire sheets substantially to fill these openings, so that small bodies of the plastic material are afforded in the individual meshes while the surfaces of the wires may be left typically exposed. 'I'he plastic material is then permitted to dry upon the form for a period, for example, of the order of forty-eight hours. While each localized portion of the material within a single mesh of the wire has some tendency to shrink, the natural adhesion of the material to :the wire is effective in holding the material in place as shrinkage takes place.

After the wire meshes have thus been iilled with the plastic material and it has been permitted to set for a period, for example, of the order of forty-eight hours, successive thin iilms or coatings of the material may be disposed over the rst layer, these coatings having a strong adhesive engagement with the previously applied layer or layers so that the tendency to shrink does not cause cracking or rupture of the material. In providing a hull of typical wall thickness, as many as three successive illms of the plastic material may be applied to the original layer at intervals of the order of twenty-four hours apart. Successive films or coatings coalesce with each other, thus in eiect aording an outer layer i6 of the plastic material upon the meshed wire which is secured to the form.

At the rear of the boat the marginal portions of the wire sheets lll and the brads 'I2 are covered by a thin layer of the plastic material which may extend over the entire surface of the stern board, this material having the ability to form a strong adhesive bond with the wood of the stern board and keelson strip.

It is evident that the margin of the outer plastic layer I8 is disposed along the line L which may conveniently be marked on the form, so that the edges of the wire sheets I0, which are secured to the form, are left exposed to permit their convenient detachment.

Plastic material of the preferred type sets rapidly due to evaporation of the solvent, whereupon it attains its permanent characteristics, in contrast to compositions which dry due to oxidization and thereafter tend .gradually to age and become brittle.- However, the employment of a plastic composition of the character disclosed herein results in a definite tendency towards shrinking as drying takes place. This method of applying the viscous compound to the meshed Wire upon a form is particularly advantageous in permitting the successful employment of a composition including a volatile solvent despite the tendency to shrink. As the solvent leaves the compound upon the form, the wire sheets are pressed firmly against the form. The original small bodies of plastic material which are disposed within the meshes of the wire sheets typically have a sufficiently strong adhesive attachment to the surrounding wires so that the tendency toward shrinkage is not effective in causing their edges to break away from the wires during setting. Thus the wire not only affords a backing to facilitate the setting of the original coating of the plastic material, but it also affords a backing to oppose any major tendency of the shrinking of successive coatings of the plastic material to cause cracking. It is evident that the successive coatings which are applied above the original material disposed within the mesh Wire coalesce and join integrally with the previously applied material due to the pressure of troweling and the natural tendency of the solvent of the outer layer to penetrate the adjoining inner layer. Obviously the form itself holds the wire against appreciable distortion under the contractive effect of the setting material. Thus this method of applying the plastic material to the core wire is particularly effective in assuring the formation of a hull of the proper symmetrical contour and in permitting the formation of an integral structure Without cracking or warping.

After the plastic material has hardened on the form, the exposed edges of the wire sheets may be detached from the form and the partially constructed hull may be lifted from the same. During this operation the sheet material which is disposed betweenv the form and the wire mesh permits ready separation of the form and hull. 'I'he paper and cloth may then be peeled from the hull.

'I'he partially formed hull at this stage may be conveniently disposed in a suitable stand, as shown in Fig. 3, and the exposed wire edges may be cut oif so that the wire ends are substantially flush with the edge of the plastic material. An inner lamina of the plastic material then may be applied, as by troweling, to the exposed inner surface of the meshed sheets l0, this material having the ability to coalesce with the outer lamina so that an integral structure or matrix body is provided within which the wire sheets are embedded. To form the inner lamina two sucbe smoothed by any suitable wood working operation as, for example, by sandpapering, thus to remove surface irregularities. At this stagefif desired, a thin cellulosic finishing coat may be applied to the entire surface of the hull by bushing or spraying, this coating being, for example, similar to conventional cellulosic lacquers and affording a smooth finish for the hull bodem The walls of the hull body may be relatively thin, for example, of the order of one-quarter inch to three-eighths inch in a ten or twelve foot boat. Due to the natural strength of the matrix body with the core layer embedded therein, ribs or stringers are not necessary to reinforce the hull wall. Since the set plastic material itself is naturally buoyant, the thin-walled hull may be light in weight.

When constructing a boat, I ordinarily secure auxiliary wooden parts to the hull. Thus, as Yshown in Fig. '7, the keel 20 may be secured to the keelson strip 4 and the hull byscrews 2l extending through the keel and hull into the keelson strip, while the inner and outer rails 2B and 29 may be conveniently secured in place by any suitable fastening means such as screws or bolts. At the front of the boat a conventional brace 21 for the prow may be located between the inner I rails 28, as shown in Fig. 6, while similar braces 39 may be located between the inner rails and the stern board.

Preferably the thwarts or seats 30 may be suspended from the rail structure by means of hangers 3| secured to the seats and gunwale strips 28, as shown in Fig. 7. The ends of the seats may conveniently abut or be juxtaposed to the inner surface of the hull but the main structural support therefor is afforded by the hangers 3l.

Plastic material of the type referred to herein is particularly adaptable to Working with wood working tools and may form a bond with wooden elements such as the keelson and stern board, while wooden parts such as the skeg, gunwale strips, thwarts, masts, rudder, etc. may be secured to the hull as desired. The only parts of a boat of this type which require special finishing are the wooden parts such as referred to above. The body of the hull itself may receive the usual conventional finishes, such as paint, varnish, or cellulosic finish, but it may remain unfinished and yet afford Wearing qualities permitting it to be frequently dragged over a pebbly or sandy shore, or to constantly rub against a Wharf Without harm. If desired, pigment may be included in the plastic material in place of some of the wood flour or other ller, thus permitting the hull to have a natural finish or distinctive color which will last indefinitely.

The principles of this invention are widely adaptable to meet various requirements. The plastic material may be conveniently employed to form deck structures or the like to be integrally joined with hull structures as, for example, in constructing duck boats. 'I'he plastic material lends itself to shaping in practically any desired form and readily receives fastening means such as nails or wood screws. A hull of this type is adapted to withstand the severe conditions to which boats are subjected, as for example, extremes of temperature, alternate immersion and to bumping against rocks, wharves, and the like. Furthermore, in case of a major shock resulting in vcr/acking of the'hull, it may readily be repaired by patching with the viscous plastic material.

In general, therefore, this invention permits the provision of a boat .which possesses the structural advantages of a conventional wooden boat without the attendant disadvantages of numerous seams and joints and the need for frequent repainting. Furthermore, this invention permits a light weight hull to be provided at a cost distinctly lower than that of a wooden hull of comparable weight.

It should be understood that the present disclosure is for the purpose of illustration only and that this invention includes all modications and equivalents which fall within the scope of the appended claims.

I claim:

1. Hull comprising an integral matrix body of set cellulosic material including a plasticizing ingredient and a comminuted filler, a core layer of readily deformable wire sheeting embedded in the matrix body, a keelson strip, the core layer com" prising two wire sheets each being substantially coextensive with one side wall of the hull, the adjoining margins ofthe sheets being connected to the keelson, the matrix body having a hrm acihesive bond with the wire and with the keelson strip, and a stern board covered by an integral continuation of the matrix body, one end of each wire sheet being connected to said board.

2. Hull comprising an integral matrix body of set cellulosic material including aiplasticizing ingredient and a comminuted filler, a core layer of readily deformable wire sheeting embedded in the matrix body, a keelson strip, the core layer comprising two wire sheets each being substantially coextensive with one side wall of the hull, the adjoining margins of the sheets being connected to the keelson, the matrix body having a rm adhesive bond with the wire and with the keelson strip, the wire sheets each having an lend bent back and secured to the sheet on the other side of the hull thus to define a generally pointed prow, and a stern board covered by an integral continuation of the matrix body, one end of each wire sheet being connected to said board..

3. Method of making a hull involving the employment of a form having a contour substantially like that of the interior of the hull, comprising securing a layer of deformable. foraminous sheet material on the form to conform to the general shape thereof, applying a layer of plastic material to the layer of sheet material so that the material is pressed into the openings of the sheet layer, removing the partially formed hull from the form after the plastic layer has set, and applying a second layer of plastic material to the inner surface of thel sheet material so that it will coalesce with the outer layer, thereby providing a hull with an integral matrix body of set plastic material with an embedded core sheet layer.

4. Method of making a hull which comprises first making a form substantially to dene the interior shape of the hull, placing a layer of sheet material on the form, locating a layer of meshed wire over the sheet material, securing the wire over the form, covering the wire with a layer of viscous compound capable of setting upon evaporation of a volatile solvent, removing the wire and set material from the form after substantial evaporation of the solvent, separating the sheet material from the set material, and applying a v 2,008,186 'exposure to the sun on a dry beach, or shocks due second layer of the viscous compound to the surface thus uncovered so that the two layers of com-l pound coalesce, thereby providing a hull with an integral matrix body of set material in which the meshed wire is embedded.

5. Method of making a hull which comprises ilrst making a form substantially to denne the shape of the interior of the hull, placing a layer of sheet material on the form, locating a pair of meshed wire sheets on the form, and interconnecting the margins of the sheets in the region of the longitudinal median plane of the form, connecting the ends of the sheets to each other, covering the wire with a layer of plastic cellulosic material including a plasticizing ingredient, a volatile solvent and afiller, removing the wire and set material from the form after evaporation of the solvent, peeling the sheet material from the set material and covering the inner surfaces of the wire sheets with plastic vmaterial so that it coalesces with the first layer of plastic material, thereby providing a hull with an integral matrix body of set material in which the meshed wire is embedded.

6. Method of making a hull which comprises first making a form substantially to define the shape of the interior of the hull, placing a layer of sheet material on the form, locating a pair of meshed wire sheets on the form, and interconnecting the margins of the sheets in the region of the longitudinal median plane of the form,

connecting one end of each sheet to a corresponding end of the other sheet, connecting the opposite ends of the sheet to a preformed stern board, covering the Wire with a layer of plastic cellulosic material including a plasticizing ingredient, a volatile solvent and a filler, extending said layer of plastic material so that it may conceal and be bonded with the stern board, removing the wire and set material from the form after evaporation 7. Method of making a hull which comprises first making a form substantially to define the shape of the interior of the hull and having a central longitudinal groove to receive a keelson strip, placing a layer of sheet material on the form, placing a keelson strip in the groove, securing one edge of a wire mesh sheet to the keelson strip so that the margin of the wire mesh sheet overlies the strip, securing the edge of a second wire mesh sheet in a similar manner to the keelson strip, bendinglthe wire mesh sheets to conform to the shape of the form so that they substantially overlie the layer of sheet material, temporarily attaching the remote margins of the wire mesh sheets to opposite sides of the form, connecting the ends of the wire mesh sheets at the ends of the form, covering the wire mesh sheets and the keelson with a continuous layer of plastic material including a volatile solvent andA rial to the surface from which the sheet material Was removed, thereby providing a hull with an integral matrix bodyof set plastic material in which the meshed wire is embedded and to which the keelson strip is bonded.

8. The method of making a hull which involves the employment of a form shaped substantially to dene the interior of the hull, being provided with a pointed prow portion, a central longitudinal groove to receive a keelson strip, and a planar stern portion, comprising placing a layer of sheet material on the form, locating a keelson strip in the groove, mounting a preformed stern board against the stern portion of the form, connecting the keelson strip to the board, securing the edges of the Wire mesh sheets to the keelson strip, connecting the ends of the wire mesh sheets to the stern board, drawing the wire mesh sheets closely about the form so that they substantially lie against the layer of sheet material, bending the end of each wire mesh sheet over the pointed prow portion of the form and securing it to the other wire sheet, securing the edges of the wire sheets remote from the keelson to the form, applying a layer of plastic material including a volatile solvent to the Wire sheets and applying a continuation of this layer to the stern board, while leaving the edges of the sheets which are connected to the form free from covering by the layer of plastic material, disconnecting these exposed edges of the sheets from the form after the plastic material has set, removing the resulting partially formed hull from the form, peeling the layer of sheet material from the inside of the partially formed hull, and applying an inner layer of plastic material to the inner surface of the partially formed hull, thereby providing a hull comprising a matrix body of set plastic ma.- terial, including a core layer of meshed wire embedded therein and a keelson strip and a stern board bonded thereto.

9. Method of making a hull involving the employment of a form having a contour substantially like that of the interior of the hull, comprising securing a layer of deformable meshecl wire tightly over the form to conform to the general shape thereof, filling the meshes of the Wire with a viscous compound capable of setting upon evaporation of a volatile solvent, thus providing bodies of the compound in the respective meshes While typically leaving the surfaces of the wire more or less exposed, permitting the bodies of compound to set due to loss of volatile solvent and thereafter applying successive thin coatings of the compound over the wire and said bodies of compound to build up an outer layer of said plastic material, removing the partially formed hull from the form, and covering the inner surface of the wire'with a layer of the viscous compound.

HARRY J. GONYER. 

